PRE-FEASIBILITY REPORT

Transcription

1 PRE-FEASIBILITY REPORT Expansion of Coal washery at Gevra From 6.25 MTPA to MTPA CAPACITY (THROUGHPUT) AT DIPKA VILLAGE KORBA DISTRICT, CHHATTISGARH Submitted to: Ministry of Environment, Forest and Climate Change New Delhi Submitted by: A C B (India) Limited March 2018 Page 1 of 40

2 INDEX Paragraph Particulars Page 1.0 Executive summary 2.0 Introduction of the Project/ Back Ground information 3.0 Project Description 4.0 Site Analysis 5.0 Imports vs Indigenous Production 6.0 Proposed Infrastructure 7.0 Rehabilitation and Resettlement 8.0 Project Schedule &cost estimates 9.0 Analysis of Proposal LIST OF FIGURES AND ANNEXURES 1. Figure-1 : Location Map 2. Figure 2: Topographical map of 10 km radius study area 3. Figure 3: Google map of 15 km radius area 4. Annexure I : Material Flow Diagram 5. Annexure II : Process Flow Diagram 6. Annexure III : Plant Layout 7. Annexure IV: ETP Flow Diagram 8. Annexure V: Water Balance 9. Annexure VI: Activity Chart for fugitive Emissions Page 2 of 40

3 1. EXECUTIVE SUMMARY Sr. No. Description Details 1. Name of the Project Expansion of Gevra Coal washery of M/s. A C B (India) Ltd. at Dipka Village. 2. Plant Capacity Expansion from 6.25MTPA to16.25mtpa (throughput) 3. Plant location Village- Dipka, Tehsil- Katghora, District- Korba, Chhattisgarh 4. Geographical Co- ordinates Point A N, E Point B N, E Point C N, E Point D N, E Point E N, E 5. Location Dipka Village, Korba District, Chhattisgarh 5.1 Nearest Villages Dipka 5.2 Nearest Town Korba 5.3 Nearest Railway Station Gevra Road 5.4 Nearest Air Port Raipur 5.5 Nearest Sea port Paradeep 6. Metrological Data 6.1 Minimum temperature 9.5 C 6.2 Maximum Temperature 45.5 C 6.3 Relative Humidity Summer 25.5%, Rainy season 97.5% 6.4 Annual rainfall 1429mm 6.5 Seismic Zone Zone II 6.6 Climate condition Moderate 7. Topography and soil condition. 325m above mean sea level. Land is fairly flat terrain. 8. Nearest water body Pond : Adjacent SW Kholar Nala : 2.65 km NE Ahiran Nadi : 7.5 km NE Hasdeo River : 12.5 Km, E Lilagar Nadi : 6.1 Km, SW Saliha Nala : 3.0 Km, N 9. Sanctuaries / National Parks / Biosphere etc Distance from boundary of Achanakmar Tiger Reserve is 70 Kms. Distance from Eco-sensitive boundary of Achanakmar Tiger Reserve is 67 Kms. Distance from Crocodile Park is 42 Kms. 10. Forest Dense mixed Jungle: 0.65 km W Open Mixed Jungle : 4.1 Km, WNW Dense Mixed Jungle : 6.2 km NNE Open Mixed Jungle: 6.4 Km, SW Open Jungle : 7.2 Km, NE 11. Coal Washery Capacity (throughput) Existing: 6.25 MTPA. Additional proposed: 10.0 MTPA Total: MTPA throughput 12. Project area Additional land acres over the existing Page 3 of 40

4 Sr. No. Description Details Acres. 13. Source of Water There will be three source of water, 1) Fresh water from Kholar Nala And/or 2) Treated waste water from 2 x 135 MW TPP. And/or 3) Water reservoir constructed for storing of rain water. The capacity of water reservoir is 95000KL. 14. Source of Power 2x 30MW plant of M/s A C B (India) Ltd located at Chakabuda 15. Source of raw coal The raw coal will be sourced from Gevra OCP (4.3km), Dipka OCP (3.7km) and Kusmunda OCP (10km) of South Eastern Coal Fields Limited. 16. Transportation - Raw Coal Trucks - Clean Coal Trucks/ Rail - Rejects Trucks 17. Dispatch arrangement Junadih Railway siding, leased by SECL situated at an aerial distance of 1.5 km and proposed railway sidings of ACBIL on the rail corridor from Gevra road station to Pendra road railway station. 18. Customer for clean Coal GEB, PSPGCB, RRVUNL, L&T, Cement Plants ETC. 19. Technology/ washing HM Cyclone and Jig equipment 20. Fine coal treatment Classifying cyclones, High frequency screen, thickener, Belt press. 21. Working hours The plant will operate in three shifts each of 8 hours for 357 days in a year and approximately 6000 effective annual working hours i.e. effective of 17 hours in a day. 22. Rehabilitation and Resettlement No R & R issue involved 23. Manpower (for the expansion) Approximately 150 persons during Construction Operation construction period and approximately 400 persons during operation. 24. Estimated Cost of the Project Rs Crores including EMP cost. (expansion) 2.0 Introduction of the Project and Project/ Back Ground information: 2.1 Identification of Project and Project Proponent: Coal is the most abundant fossil fuel. India is blessed with huge coal reserves. 85% of these reserves are non-coking coal, which caters to the need of power, cement and Page 4 of 40

5 sponge iron plants. However, most of these reserves are of very low grade coal. The reserves of good quality coal are fast depleting and on the other hand, the demand for coal is increasing due to higher demand from steel, power and cement sectors. In the past MoEF, GoI, had made it mandatory for Thermal power plants to use washed coal below 34% ash, which are located beyond 1000km from pit head (now the same was revised to 500km), or located in sensitive/ critically polluted areas. Coal from Korba area coal fields being of low grade requires washing. In order to meet the stipulations of MoEF, the coal is required to be washed at pit head before dispatching to the distant consumers. Further SECL is contemplating to enhance the production of non-coking coal (low grade) from existing Gevra open cast project from 35.0MTPA capacity to 70.0MTPA capacity and Kusmunda Open cast from 15.0 MTPA to 50.0 MTPA. The additional production from these mines may be linked to distant power houses. This situation calls for additional washing capacity requirement at pit head. M/s ACB (India) Ltd is a leader in the business of coal washing and established coal beneficiation plants in the states of Chhattisgarh, Maharashtra, Odisha and Telangana. M/s ACB (India) Ltd is contemplating to expand the existing Gevra coal beneficiation plant (washery) by installing HM cyclones and Jigs to meet the raising market demands of washed coal. Expansion portion of the Gevra coal washery is proposed to be constructed on non- coal mining area and outside lease hold area of South Eastern Coal Fields Ltd (SECL) for washing the coal produced in the Gevra, Dipka and Kusmunda Open cast projects of SECL and supply to different consumers as per market demand. 2.2 Brief Description of Plant: M/s ACB (India) Ltd is operating Gevra coal washery of 6.25 MTPA throughput capacity at Dipka village. It is proposed to increase the capacity of existing coal washery by establishing a coal washery of 10 MTPA. Thus, the total capacity of the coal washery will be MTPA throughputs. Raw coal from Gevra, Dipka and Kusmunda opencast projects of SECL will be transported to Gevra expansion coal washery by means of tipping trucks. The washery is planned to process additional 10.0MTPA raw coal and dispatch of approximately 8.0 MTPA additional clean Coal. HM cyclones and jigs will be provided for processing coarse coal. Fine coal recovery circuit will be provided for treatment of slurry so that fines are extracted and clarified water will reused for processing and thus zero discharge of effluent will be achieved. SECL has leased two numbers of platforms at Junadih (near Gevra opencast project) and another loading platform was constructed by GESB at Junadih. From the above three loading platforms washed coal will be loaded into rail wagons for dispatch to different consumers. Coal from these sidings will be dispatched to different power plants beyond 500km and also to other consumers. Rejects produced in the washery will be consumed by 2x30MW and 2x135MW power plants owned by ACBIL which are about 3 to 4 km from washery and the balance will be sold in the market to consumers using FBC/CFBC/AFBC boilers. Further ACB (India) Ltd is contemplating to establish loading platforms on the proposed rail corridor connecting Gevra road railway station to Pendra road railway station which will be nearer to the washery. The following facilities/ amenities/infrastructure will be created at site. i. Coal sampling preparation room ii. Charge Stores iii. Canteen iv. Rest shelter Page 5 of 40

6 v. Car and cycle shed vi. MCC cum control room for washery vii. Generator room viii. Fresh water reservoir with pumps ix. Reservoir for firefighting along with pump house. x. Road weigh bridges along with control room. xi. Security and time office All these facilities will be provided, keeping in mind the requirements for smooth operation of the plant and also to meet future requirements. 2.3 Need of the Project and its Importance to the Country/Region: In order to meet the demand of energy requirements of all sectors (industrial, commercial, house hold) in the country reliable and quality energy is required. About 70% of country s energy/ power requirement is generated by coal based thermal power plants. Sponge iron plants, steel plants, cement industry etc. also consume coal. Thermal power plants are designed for using certain quality of coal and any deviation in quality of coal will severely affects the performance and efficiency of the plant. Key areas of concern in coal are ash content and inconsistency in quality of coal. The performance and environmental aspects of thermal power plants largely depend on quality of coal used. Due to the above reasons emphasis has been made by Govt. of India to improve quality of coal by beneficiation and use coal with ash content of 34% in thermal power plants located beyond 500km from coal producing points and also in those power houses situated in environmentally sensitive areas. Due to the above facts there will be good market for washed coal. Following factors need to be evaluated for need of washing of coal - Economy in long distance transportation of raw coal - Poor performance and efficiency of plant using unwashed coal - Ash management - Multiplicity of supply sources in many cases add to inconsistency in quality coal - Due to the above facts there will be good market for washed coal. 2.4 Benefits of using Washed Coal: Benefits of using washed coal are given below: - Increased power generation efficiency, mainly due to the reduction in energy loss as inert material passes through the combustion process - Improvement in plant utilization factor resulting in increased plant availability - Reduced investment costs - Reduced operation and maintenance (O&M) costs due to less wear and reduced costs for fuel and ash handling - Energy conservation in the transportation sector and lower transportation costs - Less impurities and improved coal quality thus reduction in fuel consumption - Reduced smoke and dust emission thus reduction in load on the air pollution control system - Reduction in the amount of solid waste that has to be disposed off due to low ash. Due to this there will be reduction in ash disposal area - Reduction in auxiliary power consumption - Reduction /elimination in fuel oil support - Reduction in furnace wall slagging, boiler tube leakage, clinker formation, abnormal erosion etc. - Improvement in boiler efficiency and reduction in running maintenance of boiler and its auxiliaries Page 6 of 40

7 - Reduction in outage/down time in coal mills due to absence of foreign material. From the above it can be seen that washing of coal will help us in achieving operational efficiency and better performance of thermal plants thus plays a vital role in national as well as regional interest. 2.5 Demand-Supply Gap: About 2,93,497 Million tons of Geological reserves of coal up to a depth of 1200m was proved by different exploring agencies such as GSI, CMPDI, SCCL, MECL, DGM (Maharashtra) and DGM (Chhattisgarh) as on In India, thermal power plants are accounting for about 72% of total consumption. This demand has been projected based on total generation capacity envisaged in successive five year plan periods. The estimation of long term coal demand for other utilities, except iron & steel, cement, are difficult due to factors like rapid changes in the relative availability and prices of different fuels as well as the technological changes etc. The expert committee on integrated Energy Policy has estimated the long term power demand and non power demand based on the growth projections made by different agencies. The committee has made an assessment of the requirement of coal under different scenarios using multi-sector, multi period optimizing linear programming model. The alternative scenarios considered by the committee are: Coal dominant scenario: with maximum coal based electricity - Maximum development of hydro, nuclear and gas based generation - Low coal scenario: maximizing efficiency and contribution from renewable energy source. Based on various estimates one possible scenario of sector wise demand of major industry groups has been projected as given below: The demand for non-coking washed coal has significantly increased in view of the Ministry of Environment and Forests Notification on use of coal with ash content not more than 34% in power plants located beyond 500 km from the pit head and in urban area or sensitive area or critically polluted area. The Government has also laid thrust on adoption of Clean Coal Technologies (CCTs) to mitigate adverse impact of coal usage on the environment. 2.6 Import vs Indigenous production: Raw coal will be obtained from Dipka, Gevra and Kusmunda open cast mines of South Eastern Coal Fields. Landed cost at destination i.e. at users place for indigenous washed coal will be much cheaper than the imported equivalent quality coal. Due to this there will be some saving in Valuable foreign exchange and conserve the abundantly available low grade coal in our country. 2.7 Export possibility: The demand for indigenous coal is too much so washed coal may not be exported. 2.8 Domestic/ Export Markets: Presently, Coal Washeries established in India are not able to meet the beneficiated coal requirement so there is no possibility of exporting the washed coal. Page 7 of 40

8 Some of the domestic power plants linked to the mines of Korba coal field along with the distances are given below: S.No. Particulars State Distance (km) 1 Koradih Maharashtra JP Binal Thermal Power plant Khaperkheda Maharashtra Shree Siingaji TPP Madhya Pradesh Emco Energy Ltd.-I Maharashtra Emco Energy Ltd.-II Maharashtra Ratan India Amaravati-I Maharashtra Ratan India Bulls Amaravati-II Maharashtra Chandrapur Maharashtra Chandrapur I&II Maharashtra Kota Rajasthan Ramagundam Telangana Kota Rajasthan Kota unit 7 Rajasthan Nasik Maharashtra AEC Torrent (SBT) Ropar Punjab Suratgarh Rajastan Gandhinagar Gujarat Sikka Gujarat Wanakbori Raipura TPP 1- Nabha Punjab Ukai Gujarat Reliance Infrastructure Limited Ideal Energy Project, Nagpur Maharashtra Jhabua Power Ltd, Seoni Madhya Pradesh Ratan India, Nasik Maharashtra Employment Generation (Direct and Indirect) due to the project: There is direct and indirect employment opportunity by virtue of establishment of the expansion phase of Gevra washery. Local areas will be benefitted by way of generation of employment opportunities, increased demand for local products and services. Most of the manpower requirement of unskilled and semiskilled will be met from local source and peripheral villages so that there will be overall improvement in the income level of the local people. Total man power requirement during operation in the plant will be about 400 nos. With the development of the project there will be lot of scope for ancillary development in the region which in turn leads to indirect employment. There will be some improvement in educational, medical, transportation, aesthetic environment and business generation which leads to overall improvement of socio- economic status of people in the area due to implementation of the project. The plant management will be responsible for overall performance of the unit. The management will be supported by a team of highly skilled persons having varied expertise and experience, which will function individually as well as collectively for overall performance of the plant. Page 8 of 40

9 3.0 PROJECT DESCRIPTION 3.1 Type of project The proposal is for expansion of the existing Gevra coal washery from 6.25 MTPA to MTPA (throughput) capacity and is proposed for beneficiating the low grade raw coal to reduce ash content in the finished product. It may receive raw coal from the nearby open cast coal mines such as Kusmunda, Gevra and Dipka of South Eastern Coal Fields Limited. The washed coal will be dispatched to Thermal power plants linked to Korba Coal field mines of South Eastern Coal Fields limited. 3.2 Location The washery will be located near the Gevra Open Cast project of South Eastern Coal Fields Limited. The nearest village is Dipka. The village falls in the Survey of India Topo sheet No.64J-11 (Topo sheet attached). The co-ordinates of the expansion project are as given below: Point A E, N Point B E, N Point C E, N Point D E, N Point E E, N The proposed expansion project is located at a level of approximately m above mean sea level (MSL). The project is well connected by all-weather road to the district head quarter Korba which is about 20 km. The nearest railway station is Gevra Road situated at a distance of 10 km. The nearest airport is at Raipur, the state capital which is about 200 km. The nearest sea port is Paradeep, which is about 680 km. The site for construction of expansion portion of washery will be adjacent to the existing Gevra washery. Map showing the location of Project is given in Figure 1. Topographical map showing the location of project is given in Figure 2. Google map showing area within 10 km radius of the project boundary is given in Figure 3. Page 9 of 40

10 FIGURE 1: LOCATION MAP OF THE PROJECT Page 10 of 40

11 FIGURE 2: TOPOGRAPHICAL MAP OF 10 KM RADIUS STUDY AREA Page 11 of 40

12 FIGURE 3: GOOGLE MAP OF 15 KM RADIUS AREA Page 12 of 40

13 3.3 Details of Alternate sites: Not applicable as it is an expansion report. 3.4 Size or magnitude of operation Existing Gevra Coal Washery is operating at 6.25 MTPA throughput capacity. The proposed expansion portion of the washery will have a capacity to process 10.OMTPA of raw coal to produce about 8.0MTPA clean coal. Thus, total throughput capacity of the Gevra coal washery will be MTPA. 3.5 Project description with process details An approval was given by Chhattisgarh Environment Conservation Board for washing 6.25 MTPA raw coal and it is in operation. The proposal is to expand the existing capacity from 6.25 MTPA to MTPA Existing Arrangement: The existing coal washery was designed to wash 6.25MTPA raw coal. For this purpose two numbers of modules were constructed. Coal Washery is divided into four sections namely raw coal section, washing section, fine coal treatment section and dispatch section. The Equipment block diagram is shown below: Page 13 of 40

14 Raw Coal Section (Identical in both the modules): Trucks form Gevra /Dipka Opencast projects discharge coal in the overhead truck unloading hoppers each of 60t capacity. A plate grizzly with 200x200mm openings is provided over the receiving hoppers to retain over size lumps to be broken manually. In case CHP is under break down coal is unloaded in the raw coal yard which is reclaimed as and when required. Coal from truck unloading hopper is reclaimed and loaded on a belt conveyor for carrying and discharging on two numbers of double deck vibrating screens each of 400tph capacity. Primary screen segregates raw coal in to three fractions namely (+) 200mm, (+) 15 mm to (-) 200mm and (-) 15 mm size. Page 14 of 40

15 A belt conveyor carries (+) 200mm size coal from primary screen up to rotary breaker for discharging in the rotary breaker. In the Rotary breaker coal is broken to (-) 50 mm size and collected from below and hard material which is not broken comes out of rotary breaker as rejects. Impact crusher crushes the hard material to 50mm. Coal from impact crusher and rejects from rotary breaker are stored in an overhead hopper and from below the hopper coal is loaded into trucks for recycling the same. This circuit is common for both the modules. (+) 15 mm to (-) 200mm size coal from the primary screen is discharged to double roll crusher for crushing coal from 200 mm size to (-) 50 mm size. (-) 15 mm size coal from below the primary screens is collected on belt conveyor and taken to overhead steel hoppers for storage and dispatch by trucks. Crushed coal from the crushers and rotary breaker is carried to two numbers of double deck vibratory screens (secondary) each of 400tph capacity. The top deck of secondary screen will have 50mm openings and the bottom deck will be with 15 mm openings. (+) 50mm size coal retained over top deck is recycled to crusher for crushing. (-) 15 mm size coal will be taken to fine coal hopper. (+) 15 mm and (-) 50mm size fraction is carried to surge bunker for storage and feeding to barrel washer at a regulated rate. List of major equipment and items provided in the raw coal circuit will be as given below: S.No Particulars Module 1 Module 2 Remarks 1 Truck receiving hopper of 60t 1 1 capacity 2 Primary screens, double deck (Top deck with 200mm openings and bottom deck with 15mm openings), 400tph Rotary breaker (120 to 150tph), l 1 Common for both modules 4 Impact crusher, 100tph capacity and 1 Common for suitable for crushing 200mm size both modules fraction to (-) 50mm 5 Double roll crusher, 400tph, suitable 2 2 for crushing (-) 200mm lumps to (-) 50mm 6 Secondary screen, Double deck ( top 2 2 opening 50mm, bottom deck 15mm), 400tph 7 Overhead hopper for Storage and dispatch of (-) 15mm size fractions, 80t capacity 8 Overhead hopper for Storage and dispatch of rejects from rotary breaker 9 Overhead Surge hopper of 50t capacity for storing (+) 15 mm to (- 0 )50 mm size fraction 10 Associated belt conveyors 2 Common for both modules 1 Common for both modules 1 1 Page 15 of 40

16 Washing Section: Barrel washers are used for beneficiating the raw coal of size (+) 15 mm to (-) 50mm size. Barrel washer consists of a cone, Barrel and Trammel. Barrel rotates at a predetermined speed, making the feed to roll inside the barrel, resulting in stratification of coal particles according to density, the heaviest settling at bottom. Barrel is fitted internally with specially designed spirals. The spiral action generated due to rotation of the barrel makes the heavier material lying at the bottom to move backward i.e. to the feed end of the barrel and is discharged as reject. The lighter material in the upper stratified layer is carried down by the flow of the fluid to the lower end of the barrel i.e. the discharge end and is collected as de-shaled coal. Dewatering screens will be used at both ends of the Barrel for dewatering of rejects and clean coal and then transport to respective overhead hoppers for storage and dispatch to siding. Trammel provided at discharge end of barrel washer will also be used for dewatering of washed coal. Slurry is stored in a slurry tank and pumped to classifying cyclone for fines recovery. List of major equipment involved in Barrel washer section are given below: S.No Particulars Phase 1 Phase 2 Remarks 1 Barrel washer, 10 x40 size (300tph) for 1 1 washing (+) 15 mm to (-) 50 mm size fraction 2 Dewatering screen for rejects 200tph 1 1 capacity 3 Dewatering screen for clean coal 250tph capacity Slurry pump Fresh water pump Fine Coal Circuit: Fine coal circuit is common for both the modules and is planned to achieve zero discharge of effluent. Slurry from the slurry tank at barrel washer house is pumped to classifying cyclones. Over flow from the cyclone is taken to an overhead thickener and under flow is taken to high frequency screen for dewatering purpose. Over flow from high frequency screen is taken to clean coal conveyor and under flow is taken to second set of classifying cyclones. Overflow from the second set of classifying cyclones is taken to thickener and under flow to second high frequency screen. The under flow from second high frequency screen is taken to thickener and over flow to clean coal conveyor. Chemicals will be dosed at thickener for fast settlement of fines. Under flow from thickener is taken to a belt press for dewatering of the slurry. Over flow i. e. clarified water will be pumped to clarified water tank from where it will be pumped to barrel washer for reuse. At the belt press also chemical is sprayed for faster separation of liquid and solid. Coal cake from belt press is mixed with clean coal or rejects as per requirement. Under flow from belt press is pumped to thickener. Slurry ponds are provided to receive under flow from thickener in case thickener is out of order. Required pumps are provided at thickener and slurry ponds. The scheme is shown in Figure below and the list of Major equipment provided in this circuit is as given in Table below: Page 16 of 40

17 G E V R A COA L W A SH E R Y W A T ER CIR CU IT DIA GR A M HYDRO CYCLONE-I H/F-SCREEN-I BARREL WASHER-I BARREL WASHER-II INDEX SLURRY TANK SLURRY TANK PUMP WATER PUMP SLURRY COAL HYDRO CYCLONE-II STAND BY THICKNER THICKNER PUMP PUMP H/F-SCREEN-II BELT CONVEYOR DUST EXTRACTION OVER HEAD TANK VALVE SUMP COLLECTION OF BELT PRESS EFFLUENT PUMP PUMP BELT PRESS PUMP SLURRY/EFLUENT WATER TANK FRESH WATER O/F THICKNER CLARIFIED WATER TANK S.No FRESH WATER TANK FRESH WATER TANK I PUMP FRESH WATER TANK II Particulars Set of classifying Cyclones High Frequency Screen Overhead thickener, 7.5m dia. Belt Press Thickener under flow pumps Belt press effluent pump Slime pond overflow pumps Chemical dosing plant Thickener Under flow pump Belt wash pump OVER FLOW WATER TANK WATER PIPE LINE FROM 30MW POWER PLANT Remarks 2sets 2nos. 2nos. 1nos 2nos. 1nos. 2nos. 2 nos. 1nos Dispatch Section: Separate overhead steel hoppers are provided for storage and dispatch of clean coal (+) 15mm to (-) 50mm size, Fine coal (-) 15 mm size, Barrel rejects and rejects from rotary breaker. Below each of the overhead hopper gates have been provided for control of coal flow from the hopper during loading of tipping trucks. Road weigh bridges are provided for weighing the trucks. Details are as given below: i. Two numbers of overhead hopper for Storage and dispatch of (-) 15mm size fractions Page 17 of 40

18 ii. Four numbers of overhead hopper for storage and dispatch of (+) 15mm to (-) 50 mm size washed coal iii. Two numbers overhead hopper for Storage and dispatch of barrel washer rejects iv. One number Overhead hopper for storage of rejects from rotary breaker and dispatch by trucks Transportation: Beneficiated/ Washed coal of 5.0MTPA will be transported to Junadih railway siding (about 1.5km Arial distance) located near Gevra Opencast project of SECL by means of tipping trucks. SECL has leased two numbers of platforms to ACBIL for loading of coal in rail wagons and third loading platform was constructed by GEB for loading the rail wagons for carrying coal to GEB. At the loading platforms pay loaders are deployed for loading rake of wagons within the time allowed by Indian Railways. The regular customers are GEB, Rajasthan RajyaVidyut Utpadan Nigam Ltd, Punjab State Power Generation Corporation Limited, L&T, Ratan India, Cement factories, Sponge iron plants etc Proposed Expansion: The proposed expansion portion of the washery will operate for effective 6000 hours annually. The hourly average capacity of the plant will be approximately 1670tph (average). After considering surges of 20% average capacity the hourly designed capacity of washery would be approximately 2000tph. The proposed washery will consist of the following sections: i. Raw coal section ii. Washing Section (HM cyclone house, Jug house) iii. Fine coal treatment section iv. Clean coal section. v. Rejects section vi. Dust suppression/dust extraction system vii. Auxiliary buildings Raw Coal Section (CHP): Two numbers of independent parallel units/modules with average capacity of 835tph and of 1000tph (peak) each will be constructed. 20% extra over the average capacity will be provided to meet seasonal variations in the production of open cast coal mines. There will be two numbers of modules to handle 5.0MTPA raw coal by each module consists of the following and is shown in the block diagram: Two numbers of overhead steel hoppers will be provided to receive raw coal from tipping trucks. Vibratory feeder (500tph capacity) will be provided below each hopper to reclaim coal from the hopper and load on to the associated belt conveyor of 1200mm wide (500tph capacity). Rod gates will be provided between hopper opening and vibratory feeder to arrest flow of coal at the time of maintenance of vibratory feeders. Each conveyor will elevate coal and discharge the same on the associated single deck primary screen (500tph capacity). At the discharge pulley of each conveyor an electromagnetic separator will be provided for removal of ferrous material. The primary screen separates coal into (-) 50 mm and (+) 50 mm fractions. The under flow i.e. (-) 50 mm fraction will be collected on a belt conveyor from below the 2 nos. of primary screens and over flow i.e. (+) 50 mm fraction from the primary screens will be discharged on a belt conveyor Page 18 of 40

19 which in turn discharges on a conveyor to feed a belt conveyor for discharging to double roll crusher. The crusher will be of 300tph capacity and suitable to crush (-) 250mm lumps to (-) 50mm size with small % of over size. The crushed coal from the crusher and the by passed coal from crusher will be collected on a belt conveyor (1100tph) which will elevate and discharge on two numbers of 600tph capacity double deck secondary vibratory screens. The top deck of the secondary screen will be suitable for separation of +50mm size lumps and bottom deck will be suitable for separation of 20 mm size lumps. The + 50 mm size coal lumps will be recycled to double roll crusher for crushing. The (+) 20 and (-) 50mm size fraction will be collected on a conveyor and transport to discharge in an overhead surge bunker of app. 500t capacity. Coal from below the surge bunker will be reclaimed with the help of vibratory feeders and discharged on a belt conveyor of 300tph capacity for elevating and discharging in the wet box provided in jig house. The (-) 20 mm size fraction will be collected from below the secondary screens on 1200mm wide belt conveyor to elevate and discharge in an overhead bunker with two discharge openings. At each discharge opening a rod gate and vibratory feeder (300tph) will be installed for reclamation and discharging on two numbers of Flip flow screens each of 300tph capacity. The over flow {+ 8 mm to 20} mm from the flip flow screens will be collected on 1000mm wide conveyor (300tph) capacity. This conveyor will elevate and discharge in a 150t capacity overhead surge bunker. Coal from below the surge bunker will be reclaimed with the help of vibratory feeder and discharged on a belt conveyor for elevating and discharging in the wet box provided in HM cyclone house. The under flow (-8 mm) of flip flow screens will be collected on a (300tph capacity) conveyor and discharged in 2x150 tons capacity overhead hopper Washing section: HM Section: In this circuit (+) 8 mm to (-) 20 mm fraction will be treated to improve the quality. The circuit is common is common for both the modules for both the modules and consists of the following: i. De- Sliming section: The raw coal conveyor from the surge bunker will discharge coal in a wet box. From the wet box the pulp will flow down on to a de-sliming screen of 600tph capacity. Water is sprayed over the de-sliming screen with the help of spray nozzles to remove slimes of 0.5 mm size. The over flow from de-sliming screen will be carried to correct media tank and under flow of de-sliming screen will be carried to fine coal tank/ classifying cyclone sump. ii. Correct Media tank & HM Cyclones: One number HM cyclone sump of suitable capacity with center tube lined with suitable liners will be provided to receive over flow from the de-sliming screen. The pulp consisting of coal, water and magnetite of required density will be pumped two numbers of HM cyclones each of 1000mm dia. through independent pumps at required pressure to separate the pulp into two fractions namely clean coal and rejects. The density of the slurry will be changed as per requirement to achieve optimum yield as per the quality Page 19 of 40

20 parameters of raw coal. The over flow i.e. clean coal will be discharged on D&R screen (single deck screen). The purpose of the D&R screen will be to drain the media and rinse off any adhered media by spraying clarified water. For this purpose the initial portion of the screen will be used for draining dense media and on the second portion water will be sprayed to rinse the magnetic particles. The over flow from D&R screen will be fed to a basket type vibrating centrifuge for removal of moisture. Coal from vibrating centrifuge will be discharged on clean coal conveyor and the slurry/ pulp will be taken to fine coal tank. Two catch pans will be provided below the D&R screen for collecting dense media in the first one and rinsed media/ dilute media in second pan. The heavy media will be taken a splitter box from where it will normally be taken to correct media tank with an option for transferring to dilute media tank. The rinsed media / dilute media will be taken to dilute media tank. The under flow (rejects) of heavy media cyclone will be taken to a horizontal refuse screen through a fixed sieve bend. The purpose of the sieve bend and screen will be to drain the media and rinse off any adhered media by spraying clarified water. For this purpose the initial portion of the screen will be used for draining dense media and on the second portion water will be sprayed to rinse the magnetic particles. After draining and rinsing the fraction retained over the screen will be discharged on rejects conveyor. Two catch pans will be provided below the D&R screen for collecting dense media in the first one and rinsed media/ dilute media in second pan. The dense media from below the sieve bend and first catch pan of D&R screen will be taken to splitter box. The heavy media from the splitter box will normally be taken to correct media tank with an option for transferring to dilute media tank. The over flow from the D&R screen will be transported to overhead hopper for storage and then loading into trucks for further transportation. Magnetite will be charged into the dilute media tank with the help of magnetite charging pump to improve the pulp density. From the dilute media tank the rinsed media will be pumped to a feed box for distributing to two numbers of wet drum magnetic separators (LIMS). Magnetic separators will recover the magnetite and transfer it to over density media tank. Over dens media tank pumps (one working and other stand by) will transfer to a splitter box provided over correct media tank. From the splitter box media will be transferred to correct media tank through density adjustment tank with a provision to transfer the over flow back to over dense media tank. The over flow from the wet drum magnetic separator will be carried to wet box for spraying. Nucleonic density gauge will be fitted before the density adjustment tank for controlling the addition of media in dilute media tank. Level monitoring and transmitting units will be provided to control the level in the heavy media sump. Pressure gauges and pressure transmitting units will be provided in the HM circuit to maintain the correct discharge pressure to the HM cyclones Jig section: In this section 20 to 50 mm size coal will be treated to improve the quality. Two numbers of jig modules will be constructed. The details of each module will be as given below: i. De sliming section: The raw coal conveyor from the surge bunker will discharge coal in a wet box. From the wet box the pulp will flow down on to a banana type de-sliming screen of 400tph Page 20 of 40

21 capacity. Water is sprayed over the banana screen (de-sliming) with the help of spray nozzles to remove slimes of 0.5 mm size. The over flow from de-sliming screen will be carried to Batac Jig. Under flow from the de sliming screen will be carried to fine coal tank. ii. Jig section: The over flow from the Jig (clean coal) will be discharged on a fixed screen. Over flow from fixed screen will be discharged on a dewatering section. Over flow of dewatering screen will be collected on a clean coal conveyor which in turn discharges in a clean coal bunker for dispatch through trucks. Under flow from fixed screen and Dewatering screen will be collected in the fine coal tank. Rotary blowers will be provided to supply required air for creating pulses in the jig chamber to accomplish separation of clean and rejects. Under flow of the Jig will be collected a bucket elevator. The bucket elevator will have perforated buckets so that water can be drained. The bucket elevator will discharge rejects over a dewatering screen. The over flow of the rejects dewatering screen will be collected on rejects conveyor which in turn discharges in a 200t capacity rejects bunker having two numbers of discharge openings. Under flow of the dewatering screen and water drained in the bucket elevator will be carried to fine coal tank Fine coal circuit: In this section 0.5 mm fraction will treated and recovered from the pulp. The details are given below: i. Two similar and independent Fine coal treatment modules one for HM module and the second for Jig module will be provided. Slurry/pulp from the fine coal tank will be pumped to a set of raw coal classifying cyclones. The over flow from the classifying cyclones will be carried to a high rated thickener (25 m dia.). The under flow from the classifying cyclones will be carried to a high frequency screen. The particles retained over the high frequency screen will be discharged on clean coal conveyor or reject conveyor as per quality parameters and the under flow from the high frequency screen will be taken to a high rated thickener. ii. Slurry/ pulp from below the high rated thickener will be pumped to a mixing tank where flocculent will be added to agglomerate the fine particles for efficient liquid and solid separation on the belt press. The mixture will then be fed to a parallel drum belt press. In the belt press the material will be pressed to squeeze the water. After wards the cake will be taken to clean coal belt conveyor and the slurry will be taken back to thickener. iii. The thickener will receive coal slurry from belt press, classifying cyclone over flow, under flow of high frequency screen through pipes. Flocculent will be added to the slurry in the thickener for fast settlement of the solid particles. Launder will be provided along the internal periphery of the thickener for collection of clarified water and then sending to clarified water tank. Provision will also be made for draining the slurry from the thickener to slime pond in case emergency Clean coal section: Coal from basket type centrifuge of HM circuit, over flow of the clean coal dewatering screen of Jig circuit, over flow from the high frequency screen and cake from belt press will be stored in overhead hoppers. Trucks will be loaded below these hoppers for transporting to the siding to dispatch by rail wagons to distant consumers Reject section: - Over flow from the rejects D&R screen of HM section, over flow from rejects dewatering screen of Jig section will be stored in overhead hoppers. Trucks will be loaded below the Page 21 of 40

22 hoppers for transporting the same to 2x30MW and 2x135MW power houses of ACB (India) Ltd for consumption. The balance rejects will be marketed for use in the FBC/CFBC/AFBC boilers Fine coal (8 mm size): Fine coal without beneficiating will be stored in the over hoppers. Trucks will be loaded below the hoppers for transporting to railway siding for loading along with the washed coal fractions as per requirement Wagon Loading section: - SECL has leased two numbers of plat forms at Junadih siding to ACB (India) Ltd for loading of clean coal through loaders. One more siding was also constructed near Junadih siding for loading of clean coal. In future ACB (India) is contemplating to establish two to three sidings connected to the proposed rail corridor from Gevra road station to Pendra road railway siding. Existing two numbers of in motion type electronic weigh bridge of 100t capacity at Junadih siding will be used to weigh loaded wagons for preparing RRs Auxiliary Services: The following auxiliary services will be provided in the washery: i. Dust suppression system with spray nozzles etc. at truck receiving station, Discharge pulley of raw coal conveyors ii. Dust extraction system will be provided at double roll crusher. The system will consist of hoods, ducts, blower, stack etc. iii. Compressed air system for purging, valve operation, cleaning iv. Firefighting system consisting of fire hydrants, Fire extinguishers, fire pumps, water tank, Fire alarm system etc. v. Slime pond equipped with over flow pump vi. Fresh water, drinking water supply system, high pressure purging system, floor cleaning Dust control arrangements: Water spraying arrangement with the help of nozzles will be provided near the truck receiving arrangement, near discharge pulley of washery feeding conveyors and other transfer points to suppress the dust. Dust extraction system will be provided at the crusher house for control of dust generated at this place. No arrangement will be provided in washing section as there will not be any production of dust due to wet coal Utilities: The following utilities will be provided i. Coal sampling preparation room ii. Charge Stores iii. Canteen iv. Rest shelter v. Car and cycle shed vi. MCC cum control room for washery vii. Generator room viii. Fresh water reservoir with pumps ix. Reservoir for firefighting along with pump house. x. Road weigh bridges along with control room. xi. Security and time office The tentative details of the equipment required for the expansion of coal washery which may vary during detailing will be as given below: Page 22 of 40

23 S.No Particulars Module-1 Module-2 A Raw coal Section 1 Truck Dump hoppers Two Two 2 Rod Gate Two Two 3 Vibratory feeders, 500tph capacity Two Two 4 Belt conveyor, RC-01 Two Two 5 Suspended type Electromagnetic separator Two Two 6 Primary screen, 500tph capacity Two Two 7 Belt conveyor Rc02 One One 8 Belt Conveyor, RC03 Two Two 9 Belt Conveyor, RC04 One One 10 Belt Conveyor, RC05 One One 11 Double roll crusher, 300tph capacity Two Two 12 Belt conveyor RC05 One One 13 Secondary screen, 600tph capacity, double Two Two deck 14 Belt conveyor, RC 06 One One 15 Belt Conveyor, RC 07for 20 to 50 mm fraction Set of 4 conveyors Set of 2 conveyors. 16 Belt Conveyor, RC 08 (recycle conveyor) for One One +50 mm fraction 17 Belt Conveyor, RC 09 (Recycle conveyor) for One One (+) 50 mm fraction 18 Rod gate Two Two 19 Feeder, vibratory, 300tph capacity Two Two 20 Flip flow screen, 300tph capacity, suitable to Two Two separate 8 mm size fractions 21 Rod gate One One 22 Vibratory feeders 0ne One 23 Belt conveyor, RC 10 for feeding 20 to 50 mm One One fraction coal to Jig 24 Belt conveyor RC-11for feeding 8 to 20 mm One One fraction coal to surge bunker 25 Rod gate One One 26 Vibratory feeders 0ne One 27 Belt conveyor Rc-13 for feeding 8 to 20 mm One fraction to HM Cyclone house 28 Belt conveyor Rc-12 for 8 mm fraction One One 29 Sector gates along with actuator two two B Washing Circuit B.1 HM Circuit for processing 8 mm to 20 mm section) 1 Sieve Bend One 2 De-Sliming Screen, 600tph capacity One 3 Correct media tank One 4 Heavy Media cyclone pump One Two 5 Heavy Media Cyclone, 1000mm dia. One One Page 23 of 40

24 S.No Particulars Module-1 Module-2 6 D&R screen for Clean coal One One 7 Basket type Centrifuge for clean coal One One 8 Sieve Bend before D&R screen for rejects One One 10 D&R Screen for rejects One One 11 Dilute media tank One 12 Dilute media tank pump One One 13 Magnetite charging pump One One 14 Over dense media tank One 15 Over dense media tank pump One One 16 Density adjustment tank One 17 Wet drum Magnetic Separator One One 18 Density Gauge and transmitting unit One One 19 Level transmitting unit One One 20 Pressure gauge and pressure transmitting unit One Two 21 Clean up pump One One 22 Plant air compressor One One B.2 Jig section 1 Sieve bend One One 2 De-Sliming Screen One One 3 Batac Jig along with accessories One One 4 Fixed screen for clean coal One One 5 Dewatering screen for clean coal One One 6 Bucket elevator for rejects One One 7 Dewatering screen for rejects One One 8 Screw type air compressor Two Two 9 Air blower Two Two 10 Clean up pump Two Two B.3 Fine coal treatment circuit 1 Fine coal tank One One 2 Fine coal tank pump Two Two 3 Set of classifying cyclones One One 4 Sieve bend before high frequency screen One One 5 High frequency screen One One 6 High rated thickener, 25 m dia. One One 7 Thickener under flow pump Two Two 8 Thickener over flow/ Clarified water pump Two Two 9 Belt press One One 10 Belt wash pump/ spray pump Two Two 11 Belt press effluent pump Two Two 12 Flocculent dosing system for thickener and belt One One press. 13 Clean up pump Two One C Clean coal and rejects section 1 Reject belt conveyors Two Four 2 Clean Coal belt conveyors Three Four 3 Road weigh bridges, 100t capacity One One Page 24 of 40

25 3.6 Raw material required along with estimated quantity, likely source marketing area of final products, mode of transport of raw material and finished product The additional requirement will be about 10.00MTPA raw coal. The sources or raw coal will be Kusmunda, Gevra and Dipka open cast mines of South Eastern Coal Fields Limited. Selection of process is based on the study of the available washability test results of coal from SECL mines in the region. It was found that in average raw coal, ash content varies from 40 % to 45.0 %. The distances of some of the mines from the washery are as given below: Kusmunda OCP Gevra OCP Dipka OCP 10.0 km 4.3 km 3.7 Km Raw coal will be transported by tipping trucks from the coal mines up to coal washery and dump in the truck receiving hopper at washery end. The finished coal linked to thermal power stations will be transported by trucks up to railway siding at Junadih which will be about 1.5km and loaded in rail wagons of Indian railways with the help of loaders. Rejects will be transported by trucks up to 2x30MW and 2x135MW power plants owned by ACB (India) Ltd which are located at a distance of approximately 3.0 to 4.0km for consumption. The balance of the rejects will be sold to the thermal power stations with CFBC/ FBC/AFBC boilers for use. Sieve analysis of Un-crushed coal (as received from mine) S.No Size Fraction Weight % TM% IM% Ash% (ADB) mm mm to (-) 50 mm mm to 20 mm mm Average % Sieve analysis of crushed coal to (-) 50 mm S.No Size Fraction Weight % TM% IM% Ash% (ADB) mm mm to (-) 50 mm mm to 20 mm mm Average % Float and sink Analysis of mm size S.No Sp. Gravity Wt% Ash % Cumulative Floats Cumulative Sinks Wt% Ash% Wt% Ash% 1 < to to to to to to Page 25 of 40

26 S.No Sp. Gravity Wt% Ash % Cumulative Floats Cumulative Sinks Wt% Ash% Wt% Ash% to to to to to to to to Float and sink Analysis of 8-20 mm size S.No Sp. Gravity Wt% Ash % Cumulative Floats Cumulative Sinks Wt% Ash% Wt% Ash% 1 < to to to to to to to to to to to to to to Coal Analysis & Material Balance Sr. No. Properties Raw Coal Washed Coal Rejects 1 Ash % < Moisture % (total) Sulphur % GCV (Kcal/Kg) ± ±100 5 Yield % Quantity (TPA) 10,000,000 8,000,000 2,000, Resource optimization / recycling and reuse envisaged in the project, if any, should be given The washery was designed on zero effluent discharge basis so the water required will met from the recycled water and small quantities of water will be required for make-up, dust suppression, plantation and industrial use. Page 26 of 40

27 3.8 Availability of water its source, Energy/ Power requirement and source: Water Requirement: Water is required for process, dust suppression, service buildings, drinking purpose, plantation etc. Most of the requirement will be met by recycling the process. There will be three source of water, 1) Fresh water from Kholar Nala and/or 2) Treated waste water from 2 x 135 MW thermal power plant of ACB (India) Ltd. And /or 3) Water reservoir constructed for storing of rain water. The capacity of water reservoir is 95000KL. Water requirement will be approximately cum/day. The daily make up water requirement in the expansion project for various activities is given in table below: Table: Water requirement in Coal washery expansion project Sr. No. Purpose Daily Water requirement, KLD 1. Coal washing Dust suppression Plantation/Horticulture Service Buildings 8.1 Total Energy /Power Requirement and its Source: The connected load will be approximately 6500 kw and will receive power at 33kV form the nearby 2x30 MW power plant owned by ACBIL through a 33kV overhead line. Diesel generators will be provided as stand- by arrangement for meeting urgent and essential loads. 3.9 Wastes to be generated (liquid and solid) and scheme for their Management /Disposal: Waste Water: Due to the closed circuit treatment there will be no discharge of waste water outside the plant premises. Loss of water is due to increase in moisture content of coal, dust suppression (roads and in the plant), plantation and use at service buildings. The domestic effluent generated at service buildings will be treated in bio digester. Thus, no effluent will be left- out off the plant premises. Hence there will not be any chance of contamination of water bodies due to proposed installation. Fines recovered from the slurry will be disposed off along with the rejects. The liquid waste generated will be treated in the plant for which equipment have been provided and the same was described in the fine coal circuit. There will not be any liquid discharge from the plant Solid Waste Generation and its Disposal: Most of the rejects produced in this plant will be consumed in the nearby 30MW and 2x135 MW power plants owned by ACBIL. Remaining will be consumed by power plants using FBC/CFBC/AFBC boilers. 4.0 Site Analysis: Connectivity: The washery will be located adjacent to the existing Gevra coal washery of ACB (India) Page 27 of 40

28 Ltd which is near to Gevra Open cast mine of South Eastern Coal Fields Ltd. (SECL). The nearest villages are Dipka, Vijay Nagar and Krishna Nagar. The project is well connected by all-weather road to the district head quarter Korba which is about 19.0 km. The nearest railway station is Gevra Road situated at a distance of 10.0km. The nearest airport is at Raipur, the state capital which is about 200km by road. The nearest sea port is Paradeep, which is about 680 km. Coal from the opencast mines of Korba Coal fields of SECL will be transported by the tipping trucks up to the receiving hopper of washery. The clean coal from the washery will be transported by trucks up to the railway siding to dispatch clean coal by rail wagons. Rejects will be transported by trucks up to the existing power plants (2x30MW and 2x135MW) of ACB (India) Ltd for consumption. 4.2 Land Form, Land Use and Land Ownership: Proposed site is of flat terrain without any surface structures. Part of the land is already owned by ACBIL. Remaining land is in the process of acquisition / diversion. 4.3 Topography: Topography is fairly flat/level. 4.4 Existing land use plan: The proposed land is non agriculture and diverted for industrial usage. No forest, National park, wild life sanctuary, eco sensitive area, water bodies exist near the proposed site. 5.0 Imports vs Indigenous production Raw coal will be obtained from mines of SECL. Cost-wise indigenous production is much cheaper than the imported equivalent quality coal. No coal will be exported. Presently, Coal Washeries established in India are not able to meet the beneficiated coal requirement. 6.0 Proposed Infrastructure 6.1 Industrial area The Land use breakup of acres of project land is as given below: S. No. Description Area in acres % area 1 Plant area Roads, ramp and pavement Service buildings Raw coal, stacking area Plantation inside the plant area Vacant place Total Residential Area : Centralised residential colonies were constructed by ACB (India) Ltd and accommodation Page 28 of 40

29 for work men can be made available to the extent possible. So no separate residential colony will be provided for this project. 6.3 Green belt: Green belt will be developed around the washery as per the rules laid down by MoEF. 6.4 Social infrastructure The canteen, rest shelter/room, recreation room, first aid center as required in the Factories act will be provided. 6.5 Connectivity: The project is well connected by all-weather road to the district head quarter Korba which is about 19.0 km. The nearest railway station is Gevra Road situated at a distance of 10.0km. The nearest airport is at Raipur, the state capital which is about 200km by road. 6.6 Drinking Water Management (Source & Supply of water) Bore wells will be dug in the plant premises and the water from bore well will be treated by means of ROs and then used for drinking. 6.7 Sewerage System Domestic effluent from plant premises will be treated in Bio disaster. The leakages in the plant will be guided to slime pond where the coal fines will be settled and clean water will be recycled for use in the washery. 6.8 Wastewater/Effluents Management Washery effluent The effluent generated during washing will be treated with the help of high rate thickeners; belt presses and slime ponds to achieve zero effluent discharge. No solid wastes will be generated Domestic effluent Domestic effluent from plant premises will be treated in Bio disaster. Treated effluent will be used for dust suppression and plantation. 6.9 Solid and liquid waste Management A. Washery Rejects: Rejects generated due to coal beneficiation will be used in the 2x30MW and 2x135 MW power plants of ACB (India) Ltd using CFBC boilers. These power plants are located at a distance of 3 to 4 km and rejects will be transported by means of trucks. B. Municipal Waste: Negligible municipal wastes will be generated, which after composing will be used as manure. There will be no domestic wastes as residential Page 29 of 40

30 buildings are not constructed in the washery premises. C. Liquid waste: The used engine oil will be stored in the barrels and sold to the authorised recyclers in the market. Domestic effluent from plant premises will be treated in Bio disaster. and treated effluent will be used for dust suppression and plantation. Process effluent from coal washing process will be treated in high rate thickener and will be recirculated in the coal washing process Power Requirement & supply source: The source of power supply is 2x30 MW power plant of ACB (India) Ltd. The required power will be made available at 33kV by tapping the existing 33kV overhead line from 2x30 MW power plant to Dipka washery of ACB (India) Ltd. 7.0 Rehabilitation and Resettlement (R & R) Plan The proposed project will be established within the already acquired land so no resettlement of displaced persons will be required. 8.0 Project Schedule & Cost Estimates Total project cost has been estimated as Rs.163,37,00,000. Broad break-up of investment is given below: Cost Estimate for the Proposed Washery The details of the equipment required in the coal washery will be as given below: S.No Particulars Qt Unit rate Amount y. 1.0 Mechanical Equipment 1.1 Feeders and gates i. Feeders, Vibratory, 500tph 4 5, 00, , 00, 000 ii Feeder, vibratory, 300tph capacity 8 4,,00,,000 32, 00, 000 iii Rod Gate 12 1, 00, , 00, 000 iv. Sector gate, actuator operated 15 2, 00, , 00, Vibratory Screens i Primary screens, single deck, 4 27, 00, , 00, tph, suitable to receive 200mm lumps and separate 50mm lumps ii Secondary screens, double deck, 4 35, 00, , 00, tph, first deck suitable for separation of 50 mm and bottom to separate 20 mm lumps iii Flip flow screens, 300tph, suitable 4 55, 00, , 00, 000 for receiving - 20 mm size lumps and separate 8 mm 1.3 Crushing section i Suspended type, Electro Magnetic separators 4 7, 50, , 00, 000 ii Double roll crusher, 300tph 4 45, 00, , 00, 000 Page 30 of 40

31 capacity suitable to crush 250 mm lumps to 50mm size lumps. 1.4 Washing Circuit i Sieve bend 5 3, 00, , 00, 000 ii De- Sliming Screen, 600tph for HM 1 28, 00, , 00, 000 circuit iii De- Sliming Screen, 350tph for Jig 2 23, 00, , 00, 000 circuit iv HM cyclone, 1000mm dia. 2 50, 00, , 00, 000 v D&R Screen, Banana screen, for 2 25,,00,,000 50, 00, 000 clean coal 250tph vi Centrifuge for clean coal, 250tph 2 45, 00, , 00, 000 vii D&R screen for Rejects, 150tph 2 17, 00, , 00, 000 viii Wet drum magnetic separator 2 20, 00, , 00, 000 ix Batac Jig, 350 tph suitable for 2 350, 00, , 00, 000 washing 20 to 50 mm size fraction x Fixed screen for clean coal 2 5, 00, , 00, 000 xi Dewatering screens, 300tph 2 20, 00, , 00, 000 capacity for clean coal xii Bucket elevator for rejects 2 35, 00, , 00, 000 xiii Rejects dewatering screen, 75tph 2 20, 00, , 00, 000 xiv Air blowers for jig circuit 4 7, 50, , 00, 000 xv Air compressor, screw type for Jig 4 5, 00, , 00, 000 circuit xvi Air compressor, screw type for 2 9, 00, , 00, 000 operation of valves, purging etc. 1.5 Fine coal circuit i Set of Classifying Cyclones 2 35, 00, , 00, 000 ii Sieve bends 2 3, 50, 000 7, 00, 000 iii High frequency screens 2 15, 00, , 00, 000 iv High rate thickener, 25 m dia. 2 35, 00, , 00, 000 v Belt press 2 150, 00, , 00, 000 vi Chemical dosing system 2 set s 1.6 Pumps i Correct media pumps, 3 7, 18, , 56, 700 ii Dilute media tank pump 2 5, 34, , 68, 200 iii Over dense media tank pump 2 1, 74, 900 3, 49, 800 iv Centrifuge effluent tank pump 2 2, 92, 500 5, 85, 000 v Fine coal tank pump 4 6, 14, , 58, 000 vi Belt press wash pump 4 1, 07, 600 4, 30, 400 vii Belt press effluent tank pump 4 3, 39, , 58, 400 viii High pressure pump for purging 4 1,02, 600 4, 10, 400 ix Thickener under flow pump 2 3, 23, 300 6, 46, 600 x Thickener over flow/ Clarified 4 5, 28, , 15, 600 water pump xi Fresh water tank pump 2 5, 28, , 57, 800 xii Magnetite charging pump 2 1, 92, 500 3, 85, 000 xiii Sump pumps 3 1, 46, 900 4, 40, 700 Page 31 of 40

32 xiv Slime pond over flow pump 2 2, 18, 100 4, 36, 200 xv Pump at water reservoir 2 4, 78, 600 9, 57, Instruments i Density gauge with transmitting 2 7, 00, , 00, 000 unit ii Level transmitting unit 2 7, 00, , 00, 000 iii Level indicators 5 3, 00, , 00, 000 iv Pressure transmitting units 3 3, 00, 000 9, 00, 000 v Pressure gauges 40 30, , 00, 000 vi On line ash analysers 6 35, 00, , 00, Misc. items i Road weigh bridge, 100t capacity 3 10, 00, , 00, 000 ii Belt weighing machines 6 2, 50, , 00, Misc. items i Technological structures like tanks, Ls 10, 72, 50, 000 supporting structures, chutes, under pans, overflow chutes, liners etc. ii Pipes, pipe fittings and different Ls 10, 00, 00, 000 type of valves iii Dust suppression/ Dust extraction Ls 1, 00, 00, 000 system iv Fire fighting system Ls 3, 00, 00, 000 v Water supply system Ls 20, 00, 000 vi Work shop equipment Ls 30, 00, 000 vii Laboratory equipment 80, 00, 000 viii Tools, tackles, and instruments 30, 00, Belt conveyors i Structures, idlers, drive units, tail units, take up units, safety items etc. 11, 52, 67, 100 ii Conveyor belting, 800mm, 1, 25, 62, mm, 1200mm and 1400mm wide 1.10 Sub Total of items 1.1 to , 04, 82, Erection and commissioning 3, 45, 24, Total of mechanical plant and 72, 50, 06, 300 equipment 2.0 Electrical equipment 2.1 Power supply, illumination, control, 21, 75, 01, 900 instrumentation, earthing, lightning protection, communication etc 2.2 DG sets 2 80, 00, Subtotal of items 2.1 and , 55, 01, Civil and structural works 3.1 Civil foundations for industrial 17, 12, 62, 500 structures 3.2 Structural Fabrication 41, 00, 60, Service buildings Page 32 of 40

33 i Substations 2 1, 16, 20, 800 2, 32, 41, 600 ii DG room 1 10, 76, , 76, 000 iii. Sampling room 1 7, 74, 700 7, 74, 700 iv Rest shelter/ Canteen 1 8, 39, 300 8, 39, Road weigh bridge foundation and 2 9, 00, , 00, 000 control room 3.5 Roads 93, 00, Raw water reservoir and pump 22, 00, 000 house 3.7 Boundary wall (2400m) , 80, 00, Total of item 3 63, 85, 54, Vehicles Bob cat, Jeep, utility van, 70, 00, 000 Ambulance 5.0 Furniture and fittings 30, 00, Environmental protection and monitoring equipment i Plantation 3, 00, 000 ii Rainwater harvesting Ls 24, 00, 000 iii Effluent treatment plant Ls 7, 00, 000 iv Water meters, ear plus 2, 00, 000 v Ambient air quality monitoring 2, 80, 00, 000 systems vi Slime pond 30, 00, 000 Sub total 3, 46, 00, Total of items 1.0 to , 36, 62, 300 say 163, 37, 00, 000 The estimated cost excludes cost of land, land development. 9.0 Analysis of Proposal (Final Recommendations0 9.1 Pollution Control Design of coal washing plant will include measures to ensure effective compliance with environmental regulations. The following measures are proposed: Ambient Air Quality Monitoring system (CAAQMS) will be installed in the washery premises for monitoring PM 2.5 & PM 10 Dust extraction / dry fog type dust suppression system to control dust from the material transfer points. Regular Water Sprinkling on coal transportation roads Plant with close circuit water circulation system so that no effluent is discharged in the open outside the plant boundary. All the process effluent will be collected in the thickener. Settled slurry of the thickener will be dewatered in a multi roll belt press. The dewatered filter cake will be mixed with the rejects. The clarified water from thickener overflow will be re-circulated to the plant for use as process water. Only make-up water requirement will be added in the clarified Page 33 of 40

34 water tank. Since the plant will be designed with close circuit water system, no treatment of the process waste water will be needed. Emergency settling ponds will be constructed to take care of any unforeseen situation like pipe line jamming or break down of thickener. The clarified water from these ponds will be recycled as process water. Separate rain water harvesting is available in the plant, which will eventually reduce ground water abstraction. Equipment like centrifuge, belt press, high frequency screen as well as thickener will be installed to maximize water recovery from the washing circuit. This will ensure water conservation. Plantation in 30.03% of the project area is envisaged. 9.2 Financial and Social Benefits The project will improve the socio-economic status of the society in the region by generating direct and indirect employment opportunities. The project will contribute additional revenue to the State & Central exchequers in the form of taxes, cess etc. The anticipated impacts of the project are explained below: Human settlement is expected to increase after this project gets operational. In the long term, the project will have impact on the population growth due to migration of people from outside area. Indirect employment opportunities will also add to this. The literacy level of the project area is likely to increase as there will be influx of many educated people taking up jobs in the project, which is likely to result in establishment of better educational facilities. The impact of the project on the civic amenities will be minimal. Various initiatives to be planned in the project area will result in improvement / up-gradation of civil amenities. The project related construction activities will benefit the local populace in a number of ways such as supply of construction labour skilled, semi-skilled and un-skilled, tertiary sector employment and provision of goods and services for daily needs including transport. The proposed project will provide employment to the skilled as well as unskilled persons. The local population will be given preference depending upon their suitability to the job requirement. Besides direct employment, indirect employment opportunities will also open up. The project will have positive impact in the region. Quality of life of the people will further improve, which in-turn will improve the socioeconomic conditions of the area. Page 34 of 40

35 Annexure -I Page 35 of 40

36 Annexure-II Page 36 of 40

37 Annexure-III Page 37 of 40